Embodiments herein relate to food products and food product carriers for electromagnetic wave food processing systems and methods.
Most food products tend to spoil relatively quickly. As such, preservation techniques have been developed over many years to extend the amount of time that a given food product will remain fresh. Food preservation techniques can include dehydrating, freezing, fermenting, pickling, acidification, curing, canning, heat treating, retort sterilization, irradiating, chemical preservation and the like.
Retort sterilization typically involves the application of heat to hermetically sealed packages of food through thermal conduction. Retort sterilization allows for packaged non-frozen and non-dehydrated ready-to-eat foods that can have a shelf life of months to years.
While food preservation techniques, such as retort sterilization, have been successful at preventing food spoilage, it has been found that such techniques can have adverse effects on food products including, diminishing taste and appearance, reducing nutritional qualities, and the like.
Another approach to sterilization and/or pasteurization has been the application of electromagnetic wave energy (such as microwave or radiofrequency wave energy). However, the use of electromagnetic wave energy for sterilization and/or pasteurization at commercial scale has proven difficult.
Embodiments herein include food products and food product carriers for electromagnetic wave food processing systems and related methods. In an embodiment, a carrier for holding food products during a sterilization or pasteurization process is included. The carrier can include a housing defining a peak and configured to receive a flexible food package such that the peak pushes into the flexible food package distorting the shape of the flexible food package. The housing can be formed of a microwave and radiofrequency transparent material.
In an embodiment, a carrier for holding food products during a sterilization or pasteurization process is included. The carrier can include a lower housing portion defining a central peak and an upper housing portion configured to fit over the lower housing portion. The upper housing portion can define a central peak. The carrier can be configured to receive a flexible food package between the lower central peak and the upper central peak.
In an embodiment, a carrier for holding food products during a sterilization or pasteurization process is included. The carrier can include a lower housing portion defining a lower half-toroidal channel and an upper housing portion configured to fit over the lower housing portion, the upper housing portion defining an upper half-toroidal channel.
In an embodiment, a method of making a food product is included. The method can include disposing a food material within a flexible food package, sealing the flexible food package, distorting the shape of the flexible food package to assume a shape that is more toroidal than its starting shape, and applying electromagnetic wave energy to the food material.
This summary is an overview of some of the teachings of the present application and is not intended to be an exclusive or exhaustive treatment of the present subject matter. Further details are found in the detailed description and appended claims. Other aspects will be apparent to persons skilled in the art upon reading and understanding the following detailed description and viewing the drawings that form a part thereof, each of which is not to be taken in a limiting sense. The scope herein is defined by the appended claims and their legal equivalents.
Aspects may be more completely understood in connection with the following drawings, in which:
While embodiments are susceptible to various modifications and alternative forms, specifics thereof have been shown by way of example and drawings, and will be described in detail. It should be understood, however, that the scope herein is not limited to the particular embodiments described. On the contrary, the intention is to cover modifications, equivalents, and alternatives falling within the spirit and scope herein.
Microwave heating of packaged food products can create conditions of uneven heating inside the packaging. Some of this can be attributed to the dielectric properties of the product being heated, the geometry of the package, and the penetration depth of the microwave itself into the product.
Package geometry is highly significant. By way of example, sharp corners on a package can become “hot spots” under microwave load (an edge effect of small mass in a powerful energy field). However, in accordance with embodiments herein, geometry can be controlled to reduce uneven heating inside the packaging.
An ideal design for microwave heating is a toroidal “donut” shape, which presents a solution to heating from both the outside and inside product surfaces, and with no sharp angles. The surface of a toroidal shape tends to heat evenly in a microwave field without zones of preferential heating. The shaping results in minimizing hot and cold spots and also minimizing unnecessary overheating to assure sterility in cold spots or zones. Unfortunately, it is difficult to design packaging in a toroidal shape. Further, a toroidal shape is generally not conducive to consumer functionality and convenience cannot.
However, in accordance with various embodiments herein, a package carrier can be used to temporarily distort packaging into a more toroidal shape such that it can be processed with a microwave or RF field while in a generally toroidal shape and then released from the package carrier to reassume its normal shape. For example, a package carrier including a press element or press plate can deflect the central portion of a pouch, narrowing the distance to the mid-point from top and bottom and causing it to assume a more toroidal shape.
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Also, the flexible food package can be of various sizes. In some embodiments, the flexible food package can specifically be a pouch, but other form factors are also contemplated herein. In some embodiments the flexible food package can have a height (such as along the axis referenced by line 3-3′) of about 2 inches to 14 inches. In some embodiments, the flexible food package can have a width (such as along the axis referenced by line 2-2′) of about 2 inches to 12 inches. In some embodiments, the flexible food package can have a thickness (shown in the cross-sectional views in
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Electromagnetic wave energy can include energy at various frequencies. For example, electromagnetic wave energy can be applied at a frequency from approximately 300 MHz to approximately 2550 MHz or between 800 MHz to approximately 2550 MHz. In some embodiments, electromagnetic wave energy can be applied at a frequency of about 915 MHz or about 2450 Mhz. In some embodiments, electromagnetic wave energy can be applied at a frequency of about 13.56 MHz to 300 MHz.
The housings of the press members can be solid, hollow, or partially hollow (e.g. 5, 10, 20, 30, 40, 50, 60, 70, 80, 90, 95, 98, or 99 volume % hollow, or an amount falling within a range between any of the foregoing). The housing can be formed of a material that is substantially transparent to electromagnetic wave energy and specifically transparent to microwave and radiofrequency wave energy. Exemplary materials that can be used to form the housings can include, but are not limited to, materials with low dielectric loss characteristics. Exemplary materials can specifically include, but are not limited to, glass (such as borosilicate glass), polymers (including, but not limited to, polyethylene, polypropylene, polycarbonate, and polytetrafluoroethylene), ceramics, composites (including, but not limited to, composites including carbon and/or glass fibers) and the like.
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In accordance with various embodiments herein, the volume of food material in the center portion 514 and/or in places representing the intersection of center or central lateral and vertical segments can be decreased through distortion of the package shape resulting from press members of a food package carrier pushing into the food package. The food material previously in the center portion 514 can be displaced and pushed into segments of the food package surrounding the center portion 514 and in so doing the mass of food material assumes a shape that is more toroidal than the configuration in which it started. In the context of a package assessed based on three lateral segments and three vertical segments, the decrease of food material in the center portion 514 by weight can be at least about 10, 15, 20, 30, 40, 50, 60, 70, 80, 90, 95, 98 or 99 percent, or can be an amount falling within a range between any of the foregoing. By definition, the amount of the increase of food material in the other areas, in the aggregate, is equal to the decrease in the center portion 514.
In some embodiments, the food material containing zone 102 (see
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It will be appreciated that press members and features thereof, including but not limited to the peak, can have various shapes, contours, and sizes. Referring now to
The peak 408 can have a width 810 and a height 812. The width 810 can be about 0.5, 0.75, 1, 1.5, 2, 2.5, 3, 3.5 or 4 inches, or can fall within a range between any of the foregoing. The height 812 can be about 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 1, 1.5, 2 or 3 inches, or can fall within a range between any of the foregoing.
Many different contours and structural features are contemplated herein, at least some of which can be configured to aid in causing a packaged food product in assuming a more toroidal shape. Referring now to
The depressions 902 can provide for an area into which the food package can expand as pressure is applied using a press element with a peak pushing into a central area of the food package. The depressions 902 can surround the peak 408 such that they form a circular or ring-like channel around the peak 408. In some embodiments, the depressions 902 can define a half-toroidal shape. The depressions 902 can have various depths and widths. In some embodiments the depressions 902 can have a depth 912 of 0.1, 0.2, 0.3, 0.4, 0.5, 0.8, 1 or 1.5 inches, or can have a depth 912 falling within a range between any of the foregoing. In some embodiments the depressions 902 can have a width 910 of about 0.3, 0.4, 0.5, 0.8, 1, 2, 3 or 4 inches, or can have a width falling within a range between any of the foregoing.
It will be appreciated that the peaks can take on various different shapes. Referring now to
It will be appreciated that food product carriers herein can include spots to hold and deform multiple food packages. Referring now to
The upper housing 406 and the lower housing 410 can be attached to one another in a manner to allow them to pivot with respect to one another in order to close around a plurality of food packages disposed therein. In some embodiments, the upper housing 406 and the lower housing 410 can be connected to one another with a hinge mechanism 1204. In some embodiments, the upper housing 406 and the lower housing 410 can be connected to one another using an element other than a hinge mechanism. However, in other embodiments, the upper housing 406 and the lower housing 410 can be configured to simply be set on top of one another and not specifically connected to one another. In some embodiments, the upper housing 406 and the lower housing 410 can be secured together with a latch or other mechanical element.
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It will be appreciated that the peaks associated with press members herein can take on various shapes. Referring now to
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As referenced above, the shaping of packages herein (temporary or permanent) results in minimizing hot and cold spots and also minimizing unnecessary overheating to assure sterility in cold spots or zones. In various embodiments herein, all portions of a food material can be brought to a specific minimum temperature for a specific amount of time with no portions or no more than a defined small portion exceeding a threshold temperature (over temperature). The threshold temperature can be either a specific temperature (absolute) or a defined number of degrees above the specific minimum temperature (relative).
In various embodiments, the specific minimum temperature can be about 165, 170, 175, 180, 185, 190, 195, 200, 205, 210, or 212 degrees Fahrenheit, or can fall within a range between any of the foregoing. The specific amount of time can be about 15 seconds, 30 seconds, 1 minute, 2 minutes, 3 minutes, 4 minutes, 5 minutes, 7.5 minutes, 10 minutes, 15 minutes, 20 minutes, 25 minutes, or 20 minutes, or an amount of time that can fall within a range between any of the foregoing.
In various embodiments, the threshold temperature (over temperature) as an absolute value can be about 180, 185, 190, 195, 200, 205, 210, or 212 degrees Fahrenheit, or can fall within a range between any of the foregoing. In various embodiments, the threshold temperature (over temperature) as a relative value can be about 10, 15, 20, 25, 30, 35, 40, or 50 degrees Fahrenheit, or can fall within a range between any of the foregoing.
In various embodiments, the defined small portion which exceeds the threshold temperature is less than about 30, 25, 20, 15, 10, 8, 6, 4, 2, or 1 percent of the total food material amount by weight, or can fall within a range between any of the foregoing.
Thermal consistency can be achieved while still providing thermal processing to achieve a desired level of microorganism inactivation. By way of example, in some embodiments, the food products can be sufficiently processed so as to achieve a 1 log, 2 log, 3 log, 4 log, 5 log, or 6 log reduction or greater in viable, vegetative microorganisms. In some embodiments the food products can be sufficiently processed so as to achieve a 1 log, 2 log, 3 log, 4 log, 5 log, or 6 log or greater reduction in microorganism spores. In some embodiments the food products can be sufficiently processed so as to achieve a 12 log reduction in spores, such as Clostridium botulinum. In some embodiments the food products can be sufficiently processed to achieve commercial pasteurization or commercial sterilization. The system can include a controller module and a controller program to calculate the total dosage of electromagnetic wave energy and determine if the prescribed lethality was achieved per station as well as total lethality.
Various methods are included herein. In some embodiments, a method of manufacturing a food product is included. The method can include various operations, including those described above. As one example, the method can include an operation of placing a food material into a food package, such as a flexible pouch or other package. The method can also include an operation of sealing the food material into the food package, using thermal, adhesive, or other techniques. In the context of pouches, or other flexible food packages, the food product can be put into a food product carrier. The food product carrier can include a peak on one or two sides (e.g., top and bottom) that pushes into flexible the food package causing a distortion of the shape of the food package into a shape that is more toroidal than its starting shape. The method can also include an operation of applying electromagnetic wave based energy to the food package. In some embodiments, such as in the context of pouches or other flexible food packages, the method can also include an operation of returning the food package to its original shape.
Pouches can be formed of various materials including, but not limited to monolayers, multilayer laminates, and the like. In various embodiments, the pouch material can be substantially transparent to microwave and/or radiofrequency radiation. In various embodiments, the pouch material can be substantially opaque to visible spectrum radiation. In some embodiments, pouches can include laminates of plastic and metal foil layers. Layers can include materials such as, but not limited to, polyesters, polyethylene terephthalate (crystallized or amorphous), polyamide (NYLON), oriented polyamide, bi-oriented polyamide, polycarbonate, polyetherimide, polyolefins such as polypropylene or polyethylene, ethylene vinyl alcohol, aluminum, aluminum oxide, or other metals, adhesive layers, and the like. Pouches can have material thicknesses of 1, 2, 3, 4, 5, 6, 7, 8, or 10 mils, or a thickness that can fall within a range between any of the foregoing thicknesses. In various embodiments, the pouch material is flexible. In various embodiments, the pouch material(s) can contain less than 0.01 wt. % metal content.
Sealing materials forming the sealing material layer (sometimes referred to as lidding materials) can be formed of various materials including, but not limited to, polyesters, polyethylene terephthalate (crystallized or amorphous), polyamide (NYLON), oriented polyamide, bi-oriented polyamide, polycarbonate, polyetherimide, polyolefins such as polypropylene or polyethylene, ethylene vinyl alcohol, aluminum, aluminum oxide, or other metals, adhesive layers, and the like. Sealing material layers can have material thicknesses of 0.5, 1, 2, 3, 4, 5, 6, 7, 8, or 10 mils, or a thickness that can fall within a range between any of the foregoing thicknesses. In various embodiments, the sealing material layer is flexible. In various embodiments, the material(s) of the sealing material layer can contain less than 0.01 wt. % metal content.
Food materials in accordance with embodiments herein can include, but are not limited to, foods of all types as well as drinks of all types, unless used explicitly to the contrary. Food materials herein can include shelf-stable food materials, extended shelf-life food materials, ready-to-eat food materials, chilled food materials, refrigerated food materials, and the like. Shelf-stable food materials/products include those where the material or product is free of microorganisms (pathogens and spoilage-causing microorganisms) capable of growing in the product at non-refrigerated conditions at which the product is intended to be held during distribution and storage. Food materials/products that can be safely stored at room temperature, or “on the shelf,” are called “shelf stable.”
Food materials herein can include acidified and non-acidified food materials. By way of example, food materials can include those having a pH of below 4.6 as well as food materials having a pH of 4.6 or higher. Food materials herein can include high nutritional density food materials. Food materials herein can include human food materials, pet food materials, geriatric food materials, food materials for at-risk populations, baby food materials, nutraceuticals, and the like. Food materials herein can include, but are not limited to, soups, soups with particulates, sauces, concentrates, condiments, salsas, dips, fruits, vegetables, nut products, grain products, pasta products, food components or ingredients, beverages of all types, dairy products, meat products, fish products, entrees, combinations of any of these, and the like. In some embodiments, food materials herein include those that remain in a flowable state after exposure to thermal energy used for sterilization and/or pasteurization. In some embodiments, food materials herein include those that can be deformed in shape, then thermally treated using electromagnetic waves, and then return to an original or default package shape.
As used herein, the term “food package” shall be synonymous with the term “food container”. Food packages/containers can include many different types including, but not limited to, jars, cans, bottles, bowls, trays, multi-pack packages, bags, sleeves, pouches, and the like. Food packages/containers can be rigid, semi-rigid, semi-flexible, or flexible. In various embodiments the food packages herein can be substantially transparent to microwave energy and/or radiofrequency wave energy.
All publications and patents mentioned herein are hereby incorporated by reference. The publications and patents disclosed herein are provided solely for their disclosure. Nothing herein is to be construed as an admission that the inventors are not entitled to antedate any publication and/or patent, including any publication and/or patent cited herein.
It should be noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. Thus, for example, reference to a composition containing “a compound” includes a mixture of two or more compounds. It should also be noted that the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.
It should also be noted that, as used in this specification and the appended claims, the phrase “configured” describes a system, apparatus, or other structure that is constructed or configured to perform a particular task or adopt a particular configuration to. The phrase “configured” can be used interchangeably with other similar phrases such as arranged and configured, constructed and arranged, constructed, manufactured and arranged, and the like.
Aspects have been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope herein. As such, the embodiments described herein are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art can appreciate and understand the principles and practices.
This application claims the benefit of U.S. Provisional Application No. 62/673,177, filed May 18, 2018, the content of which is herein incorporated by reference in its entirety.
Number | Date | Country | |
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62673177 | May 2018 | US |